MTU 20V4000C55 Operating Instructions Manual
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MTU 20V4000C55 Operating Instructions Manual

MTU 20V4000C55 Operating Instructions Manual

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Operating Instructions

Diesel engine
20V4000C55
20V4000C65
Application group 5B
MS15043/00E

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Summary of Contents for MTU 20V4000C55

  • Page 1: Operating Instructions

    Operating Instructions Diesel engine 20V4000C55 20V4000C65 Application group 5B MS15043/00E...
  • Page 2 All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH reserves the right to change, delete or supplement the information provided as and when required.

  • Page 3: Table Of Contents

    3.3 Sensors and actuators – Overview 8.6.4 Cylinder head cover – Removal and installation 4 Technical Data 8.7 Injector 4.1 Product data 20V4000C55 8.7.1 Injector – Replacement 4.2 Product data 20V4000C65 8.7.2 Injector – Removal and installation 4.3 Firing order 8.8 Fuel System...
  • Page 4 10 Appendix A 8.16.5 Charge-air coolant pump – Relief bore check 8.17 Battery-Charging Generator 10.1 Abbreviations 8.17.1 Battery-charging generator – Check 10.2 MTU Contact/Service Partners 8.17.2 Battery-charging generator drive – Drive belt 10.3 Conversion tables replacement 10.4 Tightening specifications for screws, nuts and bolts 8.18 Fan Drive...

  • Page 5: Safety

    The maintenance schedules of the manufacturer must be observed over the entire life cycle of the product. Replacing components with emission labels On all MTU engines fitted with emission labels, these labels must remain on the engine throughout its opera- tional life.

  • Page 6: Correct Use For All Products

    • With preservation approved by the manufacturer in accordance with the (→ Preservation and Represerva- tion Specifications of the manufacturer) • With spare parts approved by the manufacturer in accordance with the (→ Spare Parts Catalog/MTU con- tact/Service partner) • In the original as-delivered configuration or in a configuration approved by the manufacturer in writing (in- cluding engine control/parameters) •...

  • Page 7: Personnel And Organizational Requirements

    1.3 Personnel and organizational requirements Organizational measures of the user/manufacturer This manual must be issued to all personnel involved in operation, maintenance, repair, assembly, installa- tion, or transportation. Keep this manual handy in the vicinity of the product such that it is accessible to operating, maintenance, repair, assembly, installation, and transport personnel at all times.

  • Page 8: Safety Regulations For Startup And Operation

    1.4 Safety regulations for startup and operation Safety regulations for startup Install the product correctly and carry out acceptance in accordance with the manufacturer's specifications before putting the product into service. All necessary approvals must be granted by the relevant authorities and all requirements for initial startup must be fulfilled.
  • Page 9 Follow the applicable warning instructions pertaining to such devices. MS15043/00E 2016-04 | Safety | 9...

  • Page 10: Safety Precautions When Working On The Engine

    1.5 Safety precautions when working on the engine Safety regulations prior to maintenance and repair work Have maintenance or repair work carried out by qualified and authorized personnel only. Allow the product to cool down to less than 50 °C (risk of explosion for oil vapors, fluids and lubricants, risk of burning).
  • Page 11 Never bend lines and avoid damaging lines, particularly the fuel lines. Ensure that all retainers and dampers are installed correctly. Ensure that O-rings are not installed in a slanted/twisted condition. Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent contact with other components.
  • Page 12 During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity of the component being pressed. Working with batteries Observe the safety instructions of the battery manufacturer when working with batteries. Gases released from the battery are explosive. Avoid sparks and naked flames. Do not allow battery acids to come into contact with skin or clothing.

  • Page 13: Fire Prevention And Environmental Protection, Fluids And Lubricants, Auxiliary Materials

    The safety data sheet may be obtained from the relevant manufacturer or from MTU. Take special care when using hot, chilled or caustic materials.
  • Page 14 Compressed air Observe special safety precautions when working with compressed air: • Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of con- tainers, risks causing an explosion. • Wear goggles when blowing dirt off workpieces or blowing away swarf. •...

  • Page 15: Standards For Safety Notices In The Text

    1.7 Standards for safety notices in the text DANGER In the event of immediate danger. Consequences: Death, serious or permanent injury! • Remedial action. WARNING In the event of a situation involving potential danger. Consequences: Death, serious or permanent injury! •...

  • Page 16: Transport

    Set the system down on a firm, flat surface only. Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate. Never set the engine down on its oil pan unless expressly authorized to do so by MTU. 16 | Transport | MS15043/00E 2016-04...

  • Page 17: Lifting Requirements

    2.2 Lifting requirements Lifting requirements DANGER Suspended load. Danger to life! • Use appropriate lifting devices and appliances. • Never stand beneath a suspended load. 1 Center of gravity Take note of the engine center of gravity Refer to the installation/arrangement drawings for details of the center of gravity of the system or the center of gravity of the engine/generator.

  • Page 18: Crankshaft - Transport Locking Device

    2.3 Crankshaft – Transport locking device Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Ratchet adapter F30027340 Engine oil Transport locking device Note: The locking device protects the crankshaft bearings from shocks and vibration damage during engine trans- port.
  • Page 19 Installing transport locking de- vice on driving end (KS), variant Screw retainer (4) with spacer sleeves (5) and screws (6) on crankshaft. Spacer sleeves (5) are optional. Tighten screws (6) to specified tightening torque using a torque wrench. Name Size Type Lubricant Value/Standard...
  • Page 20 Install guard plate (3) with screws (2) and spacer sleeves (1) on flywheel housing. Store the removed parts of the transport locking device carefully for possible reuse. Installing transport locking device on driving end (KS), variant B Note: Keep guard plate and screws on the engine. They must be reinstalled when the transport locking device has been removed.

  • Page 21: General Information

    3 General Information 3.1 Engine side and cylinder designations 1 Left engine side (A-side) 3 Right engine side (B-side) 2 Engine free end in accord- 4 Engine driving end in ac- ance with DIN ISO 1204 cordance with (KGS = Kupplungsgegen- DIN ISO 1204 (KS = Kup- seite) plungsseite)

  • Page 22: Engine Overview

    3.2 Engine overview Engine overview, free end 1 Oil heat exchanger 6 Fuel priming pump 11 Automatic oil filter 2 Crankcase breather 7 Fuel filter 12 Fan drive 3 Exhaust outlet 8 Indicator filter 13 Fan clutch 4 Engine governor ECU9 9 HP fuel pump 14 Centrifugal oil filter 5 Additional fuel filter...
  • Page 23 12 Oil filler neck 5 Engine coolant thermostat, 6 Engine coolant thermostat, HT circuit Engine model designation Explanation of engine model designation 20V4000C55/20V4000C65 Number of cylinders Cylinder arrangement: V engine 4000 Series Application: Construction and Industrial, mobile Application segment: 5 or 6...

  • Page 24: Sensors And Actuators - Overview

    3.3 Sensors and actuators – Overview A Driving end (DE) 3 B5.1 - Lube-oil pressure af- 7 B1 - Camshaft speed B Free end (NDE) ter filter 8 B43 - Intercooler coolant 1 B50 - Crankcase pressure 4 B33 - Fuel temperature pressure 2 Y44 - Fan control valve 5 B48 - Fuel pressure...
  • Page 25 1 Y39 - Injector 9 Y39 - Injector 17 F33 - Engine coolant level 2 Y39 - Injector 10 Y39 - Injector 18 B34.3 - Fuel pressure be- 3 Y39 - Injector 11 M53 - EGR shutoff flap fore supplementary filter 4 Y39 - Injector 12 B10.1 - Charge-air pressure, 19 B34.2 - Fuel pressure be-...
  • Page 26 1 Y39 - Injector 6 Y39 - Injector 11 Y39 - Injector 2 Y39 - Injector 7 Y39 - Injector 12 Y39 - Injector 3 Y39 - Injector 8 Y39 - Injector 13 B10.2 - Charge-air pressure, 4 Y39 - Injector 9 Y39 - Injector 5 Y39 - Injector 10 B16 - Engine coolant pres-...
  • Page 27 1 B44.3 - Turbocharger C 4 B89 - Lambda 7 B88.2 - NOx Lambda B side speed 5 B7 - Lube oil temperature 8 B44.2 - Turbocharger B 2 B44.1 - Turbocharger A 6 B91.3 - Exhaust gas Lamb- speed speed da pressure 9 B90 - Intake air humidity...

  • Page 28: Technical Data

    4 Technical Data 4.1 Product data 20V4000C55 Legend DL Reference value, continuous power (continuously available power under standard conditions) BL Reference value, fuel stop power (maximum engine power; not available for continuous use in some applications (control settling reserves)) A Design value (value required to design an external system (plant)) R Approximate value (typical average value for information, not ideally suitable for purposes of design) L Limit value (value which must not be violated (lower limit value, min.
  • Page 29 Exhaust gas overpressure, max. mbar Maximum admissible deviation between intake air temperature measured at °C the engine and ambient air temperature (measured in the shade at a distance of approx. 8 meters or 25 feet) Fuel temperature at engine inlet connection °C Fuel temperature at engine inlet connection, max (w/o power reduction) °C...
  • Page 30 8. Coolant system (LT circuit) Thermostat: Starts to open °C Thermostat: Fully open °C 11. Fuel system Fuel pressure at engine inlet connection, min. (when engine is starting) -0.3 Fuel pressure at engine inlet connection, max. (when engine is starting) Fuel supply flow, max.

  • Page 31: Product Data 20V4000C65

    4.2 Product data 20V4000C65 Legend DL Reference value, continuous power (continuously available power under standard conditions) BL Reference value, fuel stop power (maximum engine power; not available for continuous use in some applications (control settling reserves)) A Design value (value required to design an external system (plant)) R Approximate value (typical average value for information, not ideally suitable for purposes of design) L Limit value (value which must not be violated (lower limit value, min.
  • Page 32 Fuel temperature at engine inlet connection °C Fuel temperature at engine inlet connection, max (w/o power reduction) °C 3. Consumption Lube oil consumption after 100 h of operation (B = fuel consumption per % of B 0.2 ** hour), standard value not suitable for purposes of EA system design. Please consult Application Engineering when designing EA systems.
  • Page 33 8. Coolant system (LT circuit) Thermostat: Starts to open °C Thermostat: Fully open °C 10. Lube oil system Lube oil operating temperature before engine, to °C 95 ** Lube-oil operating pressure before engine, to 7 ** 11. Fuel system Fuel pressure at engine inlet connection, min. (when engine is starting) -0.3 Fuel pressure at engine inlet connection, max.
  • Page 34 22. Sound Exhaust noise, unsilenced - BL (free-field sound pressure level Lp, 1 m dis- dB(A) tance, ISO 6798, +3 dB(A) tolerance) Exhaust noise, unsilenced - BL (sound power level LW, ISO 6798, +3 dB(A) tol- dB(A) erance) 34 | Technical Data | MS15043/00E 2016-04...

  • Page 35: Firing Order

    4.3 Firing order Number of Firing order cylinders 20 V A1-B5-A8-B7-A5-B2-A7-B10-A2-B3-A10-B6-A3-B4-A6-B9-A4-B1-A9-B8 MS15043/00E 2016-04 | Technical Data | 35...

  • Page 36: Engine - Main Dimensions

    4.4 Engine – Main dimensions Item Dimensions Total length (A) approx. 3954 mm Width (B) approx. 1635 mm Height (C) approx. 1996 mm Height (D) approx. 2229 mm Length (E) approx. 870 mm 36 | Technical Data | MS15043/00E 2016-04...

  • Page 37: Operation

    5.1 Putting the engine into operation after extended out-of-service periods (>3 months) Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. Putting the engine into operation after extended out-of-service periods (>3 months) Item...

  • Page 38: Putting The Engine Into Operation After Scheduled Out-Of-Service-Period

    5.2 Putting the engine into operation after scheduled out-of- service-period Preconditions ☑ Engine is stopped and starting disabled. WARNING In case of out-of-service periods of more than one week: Possible corrosion of components carrying air or exhaust gas due to weather conditions, e.g. rain or snow. Risk of injury by flying debris when putting the engine into operation! •...

  • Page 39: Operational Checks

    5.3 Operational checks DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running. Risk of damage to hearing! •...

  • Page 40: Engine - Starting In Manual Mode

    5.4 Engine – Starting in manual mode Preconditions ☑ Engine is not under load. ☑ External start interlock is not activated. DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 41: Engine - Stopping In Manual Mode

    5.5 Engine – Stopping in manual mode Preconditions ☑ Engine is not under load. ☑ Engine is running in manual mode. NOTICE Stopping the engine when it is running at full load subjects it to extreme thermal and mechanical stress- Overheating of and, therefore, damage to components is possible! •...

  • Page 42: After Stopping The Engine - Putting The Engine Out Of Operation

    5.6 After stopping the engine – Putting the engine out of operation Preconditions ☑ MTU Preservation and Represervation Specifications (A001070/..) are available. NOTICE Engine coolant with inadequate freeze protection. Water remaining in the pressure sensors freezes at temperatures below 0 °C.

  • Page 43: Plant - Cleaning

    5.7 Plant – Cleaning Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage is applied. Special tools, Material, Spare parts Designation / Use Part No. Qty. High-pressure cleaning unit Cleaner (Hakupur 50/136) X00056700 WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...

  • Page 44: Maintenance

    6 Maintenance 6.1 Maintenance task reference table [QL1] The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The Mainte- nance Schedule is a stand-alone publication. The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance Schedule.
  • Page 45 Task Maintenance tasks W1689 Measure valve protrusion. (→ Page 94) W1716 Clean battery-charging generator. (→ Page 149) W1817 Check coupling rods of EGR flaps for clearance. (→ Page 113) W1864 Check and clean oil indicator filter. (→ Page 127) W1940 Replace auxiliary PTO of battery-charging generator.

  • Page 46: Troubleshooting

    7 Troubleshooting 7.1 Troubleshooting Engine does not turn when starter is actuated Cause Corrective action Battery/UltraCaps low or u Charge or replace (→ manufacturer's documentation) defective u Check cable connections for secure seating (→ manufacturer's Cable connections faulty documentation) Starter: plant starter controller or 1.
  • Page 47 2. Contact Service PTOs Charge air temperature too high Cause Corrective action u Check (→ MTU test kit) Incorrect coolant concentration u Contact Service Intercooler clogged u Contact Service EGR cooler clogged u Check fans and air supply/exhaust ducts...
  • Page 48 Charge-air pressure too low Cause Corrective action u Check, clean as necessary (→ manufacturer's documentation) Air filter clogged u Contact Service Intercooler clogged u Contact Service Exhaust turbocharger defective Coolant discharge at intercooler Cause Corrective action u Contact Service Intercooler: Leaking, major coolant discharge Blue exhaust gas Cause...

  • Page 49: Engine Governor Ecu9 - Fault Messages

    7.2 Engine governor ECU9 – Fault messages Possible engine reactions to yellow alarm: Warning, power limitation / reduction, speed limitation, engine stop Possible engine reactions to red alarm: Engine stop, power limitation / reduction, speed limitation, warning 3 – HI T-Fuel Cause Corrective action The fuel temperature at sensor...
  • Page 50 10 – SS T-Coolant Intercooler Cause Corrective action The coolant temperature in the 1. Reduce power. intercooler at sensor B26 has 2. Check whether alarm 23 is pending. exceeded limit value 2. Coolant 3. Check cooler (plant side) for contamination. temperature in intercooler too 4.
  • Page 51 27 – HI Level Leakage Fuel Cause Corrective action u Contact Service. Switch F46 in the collection tank has tripped. A leak has occurred in the HP fuel system. 30 – SS Engine Overspeed Cause Corrective action Engine speed has exceeded the u If an emergency stop has been tripped by the engine overspeed limit value or the engine test, restart the engine.
  • Page 52 36 – HI ETC2 Overspeed Cause Corrective action The speed of the LP turbocharger, 1. Reduce power. B side, at sensor B44.2 has 2. Contact Service. exceeded limit value 1. The turbocharger speed is too high. Cause: Defect or malfunction of another turbocharger.
  • Page 53 63 – HI P-Crankcase Cause Corrective action The crankcase pressure at sensor 1. Reduce power. B50.has exceeded limit value 1. 2. Check air filter (plant side) for contamination. Crankcase pressure is too high. 3. Replace oil mist fine separator (→ Page 88). 4.
  • Page 54 83 – LO P-Fuel (Common Rail) Cause Corrective action u Contact Service. The HP fuel pressure at sensor B48 has undershot the limit value. Fuel pressure is too low. 89 – SS Engine Speed too Low Cause Corrective action The engine speed has undershot 1.
  • Page 55 188 – AL CAN2 Bus Off Cause Corrective action CAN bus 2 for plant-side 1. Check connection between plant-side automation and MTU automation (e.g. Murphy display) automation. disrupted or defective. 2. Contact Service. MS15043/00E 2016-04 | Troubleshooting | 55...
  • Page 56 189 – AL CAN2 Error Passive Cause Corrective action CAN bus 2 for plant-side 1. Check connection between plant-side automation and MTU automation (e.g. Murphy display) automation. disrupted or defective. 2. Contact Service. 201 – SD T-Coolant Cause Corrective action The coolant temperature sensor 1.
  • Page 57 211 – SD P-Lube Oil Cause Corrective action The lube oil pressure sensor after 1. Check engine wiring (→ Page 158). filter (B5) supplies incorrect signal 2. Contact Service. or no signal. 212 – SD P-Coolant Cause Corrective action The coolant pressure sensor after 1.
  • Page 58 221 – SD P-Diff Lube Oil Cause Corrective action Lube oil pressure sensors B5.3 1. Check engine wiring (→ Page 158). and/or B5.1 supply incorrect 2. Contact Service. signal or no signal. 222 – SD Level Leak-off Fuel Cause Corrective action The fuel leak sensor (F46) 1.
  • Page 59 232 – SD Charger 1 Speed Cause Corrective action The speed sensor (B44.1), ETC A 1. Check engine wiring (→ Page 158). side, supplies incorrect signal or 2. Contact Service. no signal. 233 – SD Charger 2 Speed Cause Corrective action The speed sensor (B44.2), ETC B 1.
  • Page 60 323 – AL Wiring Cylinder A3 Cause Corrective action Short circuit fault in injector 1. Check wiring of relevant injector (→ Page 158). wiring cylinder A3 or injector 2. Replace injector (→ Page 101). faulty. 3. Contact Service. 324 – AL Wiring Cylinder A4 Cause Corrective action Short circuit fault in injector...
  • Page 61 328 – AL Wiring Cylinder A10 Cause Corrective action Short circuit fault in injector 1. Check wiring of relevant injector (→ Page 158). wiring cylinder A10 or injector 2. Replace injector (→ Page 101). faulty. 3. Contact Service. 331 – AL Wiring Cylinder B1 Cause Corrective action Short circuit fault in injector...
  • Page 62 337 – AL Wiring Cylinder B7 Cause Corrective action Short circuit fault in injector 1. Check wiring of relevant injector (→ Page 158). wiring cylinder B7 or injector 2. Replace injector (→ Page 101). faulty. 3. Contact Service. 338 – AL Wiring Cylinder B8 Cause Corrective action Short circuit fault in injector...
  • Page 63 345 – AL Open Load Cylinder A5 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of relevant injector (→ Page 158). to cylinder A5. 2. Contact Service. 346 – AL Open Load Cylinder A6 Cause Corrective action Disruption fault in injector wiring 1.
  • Page 64 353 – AL Open Load Cylinder B3 Cause Corrective action Disruption fault in injector wiring 1. Check wiring of relevant injector (→ Page 158). cylinder B3. 2. Contact Service. 354 – AL Open Load Cylinder B4 Cause Corrective action Disruption fault in injector wiring 1.
  • Page 65 365 – AL Stop MV-Wiring Ground Cause Corrective action Short circuit of injector positive 1. Check wiring (→ Page 158). connection to ground of one or 2. Restart engine. more injectors. 3. Contact Service. Short circuit of the negative injector connection or of one or more injectors to ground.
  • Page 66 480 – AL Ext. Engine Protection Cause Corrective action External engine protection 1. Check plant signal. function is active. 2. Contact Service. 488 – HI ETC3 Overspeed Cause Corrective action The speed of the HP turbocharger 1. Reduce power. at sensor B44.3 has exceeded 2.
  • Page 67 609 – AL Wiring PWM_CM7 Cause Corrective action Cable break or short circuit at 1. Check engine wiring (→ Page 158). voltage supply of the TRICAN 2. Contact Service. (B90) or the NOx sensor (B88). 614 – AL L1 P-Fuel Add.sec.fuelfilt. Diff Cause Corrective action The differential pressure above...
  • Page 68 628 – AL Wiring PWM_CM10 Cause Corrective action Disruption or short circuit in 1. Check engine wiring (→ Page 158). wiring to servomotor of EGR 2. Contact Service. shutoff flap M53. 629 – AL EGR Throttle A Defect Cause Corrective action The EGR shutoff flap (M53) is 1.
  • Page 69 648 – SD P-Charge Air B Cause Corrective action The charge-air pressure sensor 1. Check engine wiring (→ Page 158). (B10.11) after intercooler, B side, 2. Contact Service. supplies incorrect signal or no signal. 727 – AL L1 Delta T-NT Intercooler Cause Corrective action The differential temperature at...
  • Page 70 834 – AL Gas Path Warning Cause Corrective action Emission fault summary alarm 1. Check for additional messages. 2. Contact Service. 835 – AL Gas Path Fault Cause Corrective action Emission fault summary alarm 1. Check for additional messages. 2. Contact Service. 857 –...
  • Page 71 953 – AL Lambda value invalid Cause Corrective action Status information of lambda 1. Acknowledge alarm. sensor (B89); is generated in case 2. Replace lambda sensor (→ Page 166). of short-term implausible 3. Contact Service. measured values or with faulty lambda sensor.
  • Page 72 959 – AL Lambda ctrlvar max BOI min act Cause Corrective action Emission-related alarm. 1. Check operation of EGR shutoff flap and dispenser flap This fault is a strong indication of (→ Page 113), (→ Page 159). serious soot contamination in the 2.
  • Page 73 963 – AL GPS p5 ctrlvar max active Cause Corrective action The required charge-air pressure 1. Check air filter (plant side) for contamination. could not be reached. 2. Check operation of bypass flap (→ Page 113), (→ Page 159). 3. Contact Service. 964 –...
  • Page 74 983 – AL Stop on Trigger Crashrecorder Cause Corrective action u Contact Service. The alarm indicates that the crash recorder has been triggered and, as a result, a start interlock has been activated. 1097 – AL Flap Egr A Communication Lost Cause Corrective action The ECU can no longer detect the...
  • Page 75 1109 – AL Flap Dispens Communication Lost Cause Corrective action The ECU can no longer detect the 1. Check engine wiring (→ Page 158). dispenser flap (M55) on the bus. 2. Contact Service. 1110 – AL Flap DispensTemperature too high Cause Corrective action The internal electronics of the...
  • Page 76 1122 – AL Flap BypassA Calibr. Drive Err Cause Corrective action u Contact Service. The ECU has detected a calibration run error in the bypass flap (M52). Cause: The learned rotation range (angle) during the calibration run was not plausible. The learned angle is not between a minimum and maximum permissible limit.
  • Page 77 1190 – AL Dispenser Flp Wear Limit2 Cause Corrective action Fast reference run of EGR 1. Check state of charge of batteries (plant side). dispenser flap (M55) faulty 2. Check operation of dispenser flap (→ Page 113), (→ Page 159). (executed after every ECU 3.

  • Page 78: Task Description

    8 Task Description 8.1 Engine 8.1.1 Engine – Barring manually Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Barring device F6783293 Barring device F6792918 Barring device F6798050 Ratchet with extension F30006212...
  • Page 79 Note: Use barring tool F6555766. Engage barring device (2) in ring gear of fly- wheel and mount on flywheel housing. Fit ratchet (1) on barring device. Note: No resistance other than compression resist- ance may be encountered. Rotate crankshaft in engine direction of rota- tion.
  • Page 80 Note: Use barring device F6792918. Engage barring device (1) with ring gear and mount on flywheel housing. Position ratchet (2) with socket on barring device (1). Note: No resistance other than compression resist- ance may be encountered. Rotate crankshaft in engine direction of rota- tion.

  • Page 81: Engine - Cranking On Starting System

    8.1.2 Engine – Cranking on starting system Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 0.5–5 Nm 0015384230 Sealing (→ Spare Parts Catalog) DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...
  • Page 82 Engine Control Unit with protec- tive cover Undo screws (7) on protective cover (1) and remove protective cover (1). Dry clean Engine Control Unit and connectors thoroughly. Remove connector X3 (2) as described above (→ Step 2). Crank engine in unloaded state as described above (→...

  • Page 83: Engine - Test Run

    8.1.3 Engine – Test run DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Before cranking the engine with starter system, make sure that there are no persons in the engine's danger zone.

  • Page 84: Cylinder Liner

    8.2 Cylinder Liner 8.2.1 Cylinder liner – Endoscopic examination Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Barring device F6555766 Ratchet with extension F30006212 Endoscope Y20097353 Preparatory steps Remove cylinder head cover (→ Page 99). Remove injector (→...
  • Page 85 Compile endoscopic report using the table. Use technical terms to describe the liner surface (→ Page 86). Depending on findings: • Do not take any action or • carry out a further endoscopic examination as part of maintenance work or •...

  • Page 86: Instructions And Comments On Endoscopic And Visual Examination Of Cylinder Liners

    8.2.2 Instructions and comments on endoscopic and visual examination of cylinder liners Terms used for endoscopic examination Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examina- tion report. Findings Explanations/Action Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products, particles, broken-off burrs).
  • Page 87 Evaluation of findings and further measures The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough inves- tigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To avoid unnec- essary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.

  • Page 88: Crankcase Breather

    8.3 Crankcase Breather 8.3.1 Oil mist fine separator – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Engine oil Oil mist fine separator (→...
  • Page 89 Unscrew nut (2) remove together with wash- ers. Remove cover (1) and sealing ring. Replace filter element (3). Replace seal ring as necessary. Install sealing ring and cover (1). Screw on new nut (2) with new washers and tighten nut (2) to specified torque using a torque wrench. Name Size Type...

  • Page 90: Auxiliary Pto

    8.4 Auxiliary PTO 8.4.1 Auxiliary PTO – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Grease(Kluthe Hakuform 30-15) X00067260 Engine oil O-ring (→ Spare Parts Catalog) Screw (→ Spare Parts Catalog) NOTICE Contamination of components. Damage to component! •...
  • Page 91 Remove screws (5, 6) and take off retain- ers (3, 4). Remove screws (7) together with wash- ers (8). Remove auxiliary PTO (2) with O-ring (1). Install new auxiliary PTO (2) with new O- ring (1). Install screws (8) with washers (7). Install retainers (3, 4) with screws (5, 6).

  • Page 92: Belt Drive

    8.5 Belt Drive 8.5.1 Drive belt – Condition check Preconditions ☑ Engine is stopped and starting disabled. ☑ Guard is removed. Drive belt – Condition check Item Findings Action Drive belt A Singular cracks None Drive belt B Cracks on entire circumference Replace (→...

  • Page 93: Valve Drive

    8.6 Valve Drive 8.6.1 Valve gear – Lubrication Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine oil Valve gear – Lubrication Remove cylinder head upper section (→ Page 99). Fill oil chambers of valve bridges with oil.

  • Page 94: Valve Protrusion - Measurement

    8.6.2 Valve protrusion – Measurement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Depth gauge, 200 mm Y20000918 Preparatory steps Remove cylinder-head cover upper section (→ Page 99). Remove injector (→ Page 102). Install barring device (→...
  • Page 95 Loosen adjusting screw (1, 2) and take off valve bridges (4, 5). Do not remove rocker arm (3). Measure distance between valve stem end and cylinder head top at the injector bore with depth gauge (see figure). • Specified value for a new cylinder head: 93.8 mm.

  • Page 96: Valve Clearance - Check And Adjustment

    8.6.3 Valve clearance – Check and adjustment Preconditions ☑ Engine is stopped and starting disabled. ☑ Coolant temperature max. 40 °C. ☑ Valves are closed. Special tools, Material, Spare parts Designation / Use Part No. Qty. Feeler gage Y20098771 Valve setting gage Y4349603 Angular screw driver F30002815...
  • Page 97 Note: Pointer (1) located in lower opening of fly- wheel housing (arrowed). Using the barring tool, turn crankshaft in di- rection of engine rotation until marking OT- A1/TDC-A1 on the rear side of the flywheel and pointer (1) are aligned. Diagram for 20V engines (two crankshaft positions) Checking valve clearance at two crankshaft positions...
  • Page 98 Adjusting valve clearance Release locknut (1). Insert valve adjusting gage (3) between valve bridge and rocker arm. Note: Replace or rectify adjusting screws and/or locknuts which do not move freely. Using angular screw driver, set adjusting screw (2) so that the specified valve clear- ance is provided.

  • Page 99: Cylinder Head Cover - Removal And Installation

    8.6.4 Cylinder head cover – Removal and installation Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Assembly compound (Kluthe Hakuform 30-15) X00067260 Gasket (→ Spare Parts Catalog) O-ring (→...
  • Page 100 Installing cylinder head cover Clean installation surface. Check gasket (1) for damage, replace as nec- essary. Coat gasket (1) with assembly compound. Place gasket (1) and cylinder head cover low- er section (2) on cylinder head. Install cylinder head cover lower section (2) with screws (4, 5) and washers (3, 6).

  • Page 101: Injector

    8.7 Injector 8.7.1 Injector – Replacement Special tools, Material, Spare parts Designation / Use Part No. Qty. Injector (→ Spare Parts Catalog) Injector – Replacement Remove injector and install new one (→ Page 102). MS15043/00E 2016-04 | Injector | 101...

  • Page 102: Injector - Removal And Installation

    • Seal off components with suitable covers. • Check components for special cleanliness prior to installation/assembly and clean if necessary. Label 1 DMC - Data Matrix Code 2 L'Orange part number 3 MTU part number 4 EMI-ID 5 Serial number 6 Date of manufacture Preparatory steps Close off fuel supply to engine.
  • Page 103 Removing injector Note: The cable connectors feature a latch, which is released by pulling the black connector housing backwards. Disconnect connectors on injector (arrowed). Unscrew union nuts (2, 5) and remove HP line (3) from rail (4) and cylinder head. Note: When the adapter is unscrewed, the stored volume of the injector is emptied.
  • Page 104 Install installation/removal jig (2) on cylinder head. Remove injector (1) and hold-down clamp with installation/removal jig (2). Remove installation/removal jig (2). Clean all mating and sealing surfaces. If carbon residue is present, clean sealing face on cylinder head and protective sleeve with milling cutter.
  • Page 105 Press in injector (1) and hold-down clamp with installation/removal jig (2). Remove the installation/removal jig. Coat screw head mating face on hold-down clamp (1) and screw head mating face and thread of screw (2) with engine oil. Insert screw (2) and tighten hand-tight. Note: Ensure immaculate cleanliness.
  • Page 106 Tighten screw on hold-down clamp (→ Step 9) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw Tightening torque (Engine oil) 100 Nm +10 Nm Tighten adapter (1) tighten to specified torque using a torque wrench. Name Size Type...

  • Page 107: Fuel System

    8.8 Fuel System 8.8.1 Fuel system – Venting Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Diesel fuel WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 108: Fuel Filter

    8.9 Fuel Filter 8.9.1 Fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 109: Additional Fuel Filter - Replacement

    8.9.2 Additional fuel filter – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Filter wrench F30379104 Engine oil Easy-change filter (→ Spare Parts Catalog) WARNING Fuels are combustible and explosive. Risk of fire and explosion! •...

  • Page 110: Charge-Air Cooling

    8.10 Charge-Air Cooling 8.10.1 Charge-air cooler – Leak check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 111: Exhaust Gas Recirculation

    Checking emission label Note: If there are any irregularities, notify your MTU Service contact person without delay. Check that emission labels are present (several are possible). Does the label on the engine match the label document in the Business Portal/Equipment? Check emission label for intactness.

  • Page 112: Exhaust Flaps - Overview

    8.11.2 Exhaust flaps – Overview 1 EGR shutoff flap 2 Donor cylinder flap 1 Bypass flap 112 | Exhaust Gas Recirculation | MS15043/00E 2016-04...

  • Page 113: Exhaust Flaps - Checking Coupling Rod Clearance And Function

    8.11.3 Exhaust flaps – Checking coupling rod clearance and function Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage applied. WARNING Actuation mechanism in the exhaust and intake area closes automatically. Risk of crushing hands! • To carry out the teach-in routine, keep clear of the safety zone of the actuation mechanism in the intake and exhaust area.
  • Page 114 Check operability and ease of movement of coupling rod (1) by moving it at the specified points (arrows) and make sure that there is no excessive play. Result: Replace coupling rod (1) if it is jamming, slug- gish or features excessive play (→ Page 115). 114 | Exhaust Gas Recirculation | MS15043/00E 2016-04...

  • Page 115: Exhaust Flaps - Coupling Rod Replacement

    Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 6–50 Nm F30027336 Ratchet adapter F30027340 Assembly paste (Ultra-Therm MTU) 50547 Coupling rod (→ Spare Parts Catalog) Coupling rod (→ Spare Parts Catalog) Locknut (→ Spare Parts Catalog) Locking screw (→...
  • Page 116 Tighten lever (2) with locknut (1) on output shaft to the specified tightening torque. Name Size Type Lubricant Value/Standard Tightening torque (Assembly paste (Ul- 16 Nm ±2 Nm tra-Therm MTU)) Tighten washers and locknuts (3) to the specified tightening torque. Name Size Type Lubricant Value/Standard Tightening torque (Assembly paste (Ul- 16 Nm ±2 Nm...
  • Page 117 Screw Tightening torque (Assembly paste (Ul- 10 Nm ±1 Nm tra-Therm MTU)) Note: After every change to the exhaust gas recirculation mechanical system, the DiaSys® must be used to carry out an actuator test (learning run) (→ Dialog system E531920/..).

  • Page 118: Starting Equipment

    8.12 Starting Equipment 8.12.1 Starter – Condition check Preconditions ☑ Engine is stopped and starting disabled. Checking starter condition Check securing screws of starter for secure seating and tighten if required. Check wiring (→ Page 158). 118 | Starting Equipment | MS15043/00E 2016-04...

  • Page 119: Lube Oil System, Lube Oil Circuit

    8.13 Lube Oil System, Lube Oil Circuit 8.13.1 Engine oil level – Check at sight glass Preconditions ☑ Engine is stopped and starting disabled. Engine oil level check at sight glass Make a preliminary visual check of oil lev- el (2) at the sight glass (1). A proper engine oil level check must always be carried out using the oil dipstick (→...

  • Page 120: Engine Oil - Level Check With Oil Dipstick

    8.13.2 Engine oil – Level check with oil dipstick Checking oil level prior to en- gine start Pull out dipstick from guide tube and wipe it. Insert dipstick into guide tube up to the stop, pull out after approx. 10 seconds. Check oil level on oil dipstick side marked "5 Min.

  • Page 121: Engine Oil - Change

    8.13.3 Engine oil – Change Preconditions ☑ Engine is stopped and starting disabled. ☑ Engine is at operating temperature. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 40–200 Nm F30027337 Torque wrench 300–800 Nm...
  • Page 122 Draining residual oil from equip- ment carrier (only for unsched- uled engine oil change) Provide a suitable container in which to col- lect the engine oil. Remove drain screw (1) and drain engine oil from engine oil heat exchanger and automat- ic oil filter.

  • Page 123: Engine Oil - Sampling And Analysis

    8.13.4 Engine oil – Sampling and analysis Preconditions ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. MTU test kit 5605892099/00 DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! •...

  • Page 124: Replacement

    8.14 Oil Filtration / Cooling 8.14.1 Automatic oil filter – Oil filter candles replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Assembly compound (Kluthe Hakuform 30-15) X00067260 Engine oil O-ring (→...
  • Page 125 Pull out oil filter element (1). Remove O-ring. Remove screw (2). Pull out plastic spinner (1) with spring. Remove nut (3). Take off spring washer and washer. Remove screw (4). Remove flushing arm (5) from screen plate (6). Turn filter element by 180° and use appropri- ate tool to push out filter candles (1).
  • Page 126 Installing oil filter candles Install in reverse order of removal. Additionally, the following instructions are to be observed: • Replace all seals with new parts • Apply assembly compound to O-rings • Insert O-rings in grooves • Observe position of fillister-head screw to elongated hole in shaft 126 | Oil Filtration / Cooling | MS15043/00E 2016-04...
  • Page 127 8.14.2 Oil indicator filter – Cleaning and check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Cleaner (Snow-White 11-0) X00054118 Cleaner (Hakupur 50/136) X00056700 Engine oil Strainer (→ Spare Parts Catalog) Square-section ring (→...
  • Page 128 Removing strainer Clean oil indicator filter before disassembling Remove screws (1). Take off cover (2) with O-ring (3). Take strainer (5) from filter housing. Checking strainer Item Findings Measure Strainer Metallic residues • Clean • Monitor engine operation • Check strainer daily •...
  • Page 129 8.14.3 Centrifugal oil filter – Cleaning and filter sleeve replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Torque wrench, 10–60 Nm F30452769 Cold cleaner (Hakutex 60) X00056750 Filter sleeve (→...
  • Page 130 Cleaning centrifugal oil filter and replacing filter sleeve Remove clamp (14). Release cover nut (2) and take off cover (1). Carefully lift rotor (11), allow oil to drain and remove from housing. Holding the rotor (11) firmly, release rotor cover nut (3). Take off rotor cover (4).
  • Page 131 8.15 Coolant Circuit, General, High-Temperature Circuit 8.15.1 Engine coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...
  • Page 132 Checking engine coolant level at sight glass Check coolant level (coolant level must be between “min.” and “max.” mark). Top up with treated coolant as necessary (→ Page 136). 132 | Coolant Circuit, General, High-Temperature Circuit | MS15043/00E 2016-04...
  • Page 133 8.15.2 Engine coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Engine coolant change Drain engine coolant (→ Page 134). Fill with engine coolant (→ Page 136). MS15043/00E 2016-04 | Coolant Circuit, General, High-Temperature Circuit | 133...

  • Page 134: Engine Coolant – Draining

    8.15.3 Engine coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. WARNING Coolant is hot and highly pressurized. Risk of injury! Risk of scalding! • Allow engine to cool down. • Wear protective clothing, protective gloves, and safety glasses / facial protection. Preparatory steps Provide a suitable container to collect the coolant.
  • Page 135 Drain remaining coolant at the flywheel hous- ing, A- and B-side (arrows). Final steps Tighten shutoff cock (2) at elbow of engine coolant pump with torque wrench to specified tightening torque. Name Size Type Lubricant Value/Standard Spindle 11 a/f Tightening torque 12 Nm Close all other open drain points.
  • Page 136 8.15.4 Engine coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Engine coolant WARNING Coolant is hot and highly pressurized.
  • Page 137 Filling with engine coolant using pump Connect a suitable pump with a hose to the drain screws (arrows). Open vent points on EGR cooler (1) and dis- tributor (2, 3). Open drain valve and pump coolant into en- gine at 0.5 bar minimum. Result: When coolant emerges from the vent points, close vent points one by one, proceeding...
  • Page 138 Alternatively: Filling with cool- ant through filler neck Open vent points on EGR cooler (1) and dis- tributor (2, 3). Fill engine coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant. Result: When coolant emerges from the vent points, close vent points one by one, proceeding...
  • Page 139 8.15.5 Engine coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.

  • Page 140: Breather Valve – Replacement

    8.15.6 Breather valve – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Valve breather (→ Spare Parts Catalog) WARNING Coolant is hot and under pressure. Risk of injury and scalding! •...

  • Page 141: Charge-Air Coolant – Level Check

    8.16 Low-Temperature Circuit 8.16.1 Charge-air coolant – Level check Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. WARNING Coolant is hot and under pressure. Risk of injury and scalding! • Let the engine cool down.
  • Page 142 8.16.2 Charge-air coolant – Change Special tools, Material, Spare parts Designation / Use Part No. Qty. Coolant Charge-air coolant – Change Drain charge-air coolant (→ Page 143). Fill with charge-air coolant (→ Page 145). 142 | Low-Temperature Circuit | MS15043/00E 2016-04...
  • Page 143 8.16.3 Charge-air coolant – Draining Preconditions ☑ Engine is stopped and starting disabled. ☑ No operating voltage applied. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Sealing ring (→...
  • Page 144 Drain remaining charge-air coolant at charge- air cooler (high pressure) (arrow). Final steps Close all drain valves and screw in drain plugs with new sealing rings. Put on filler neck cap and close it. 144 | Low-Temperature Circuit | MS15043/00E 2016-04...
  • Page 145 8.16.4 Charge-air coolant – Filling Preconditions ☑ Engine is stopped and starting disabled. ☑ MTU Fluids and Lubricants Specifications (A001061/..) are available. Special tools, Material, Spare parts Designation / Use Part No. Qty. Charge-air coolant WARNING Coolant is hot and under pressure.
  • Page 146 Filling with engine coolant through filler neck Open venting point at distributor (1). Fill charge-air coolant in expansion tank via filler neck until coolant level at top edge of filler neck remains constant. Check proper condition of cap and clean sealing faces if required.
  • Page 147 Open venting point at distributor (1). Open drain valve and pump charge-air cool- ant into engine at 0.5 bar minimum. Fill expansion tank until overflow edge is reached. Close drain valve. Check proper condition of cap and clean sealing faces if required. Put on filler neck cap and close it.
  • Page 148 8.16.5 Charge-air coolant pump – Relief bore check DANGER Rotating and moving engine parts. Risk of crushing, danger of parts of the body being caught or pulled in! • Only run the engine at low power. Keep away from the engine's danger zone. WARNING High level of engine noise when the engine is running.
  • Page 149 8.17 Battery-Charging Generator 8.17.1 Battery-charging generator – Check Preconditions ☑ Engine is stopped and starting disabled. WARNING Compressed air gun ejects a jet of pressurized air. Risk of injury to eyes and damage to hearing, risk of rupturing internal organs! •...
  • Page 150 8.17.2 Battery-charging generator drive – Drive belt replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Drive belt (→ Spare Parts Catalog) WARNING Spring/circlip/tensioning roller preload. Risk of injury! •...
  • Page 151 8.18 Fan Drive 8.18.1 Fan drive – Drive belt tension check / adjustment Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Belt tension tester (optibelt TT3) Y4345711 Torque wrench, 60–320 Nm F30452768 Preparatory steps Remove protective cover.
  • Page 152 Hold measuring tip of belt tension tester over belt drive. Tap drive belt (arrowed) with a suitable tool. Hold belt tension tester over belt drive until the measured value (frequency) is displayed. Initial assembly at MTU Initial operation with fan Belt tension adjustment 36 Hz ±3 Hz 48 Hz ±1 Hz...
  • Page 153 Hold measuring tip of belt tension tester over belt drive. Tap drive belt (arrowed) with a suitable tool. Hold belt tension tester over belt drive until the measured value is displayed. Initial assembly at MTU Initial operation with fan Belt tension adjustment 36 Hz ±3 Hz 49 Hz ±1 Hz...
  • Page 154 8.18.2 Fan drive belt – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 60–320 Nm F30452768 Drive belt (→ Spare Parts Catalog) Preparatory steps Remove protective cover. Remove fan.
  • Page 155 Tighten hex nut (4) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Hex nut Tightening torque 70 Nm +7 Nm Version B – fan drive without belt tensioning pulley Replacing drive belt Undo screws (2). Slacken off stud (1) until drive belt can be re- moved.
  • Page 156 8.19 Engine Mounting / Support 8.19.1 Engine mounting – Securing screw check Preconditions ☑ Engine is stopped and starting disabled Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Torque wrench, 60–320 Nm F30452768 Torque wrench 300–800 Nm F30047798...
  • Page 157 Tighten loose screw connections (4) to specified torque using a torque wrench. Name Size Type Lubricant Value/Standard Screw M20x200, Control torque (Engine oil) 500 Nm +50 Nm M20x180 Tighten loose screw connections (5) to specified torque using a torque wrench. Name Size Type...
  • Page 158 8.20 Wiring (General) for Engine/Gearbox/Unit 8.20.1 Engine cabling – Check Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 Engine cabling – Check Check securing screws of cable clamps on engine and tighten loose screw connections. Ensure that cables are securely seated in clamps and cannot move freely.
  • Page 159 8.21 Accessories for (Electronic) Engine Governor / Control System 8.21.1 Actuators – Visual inspection and test Preconditions ☑ Engine is stopped and starting disabled. WARNING Actuation mechanism in the exhaust and intake area closes automatically. Risk of crushing hands! • To carry out the teach-in routine, keep clear of the safety zone of the actuation mechanism in the intake and exhaust area.
  • Page 160 Item Findings Measure Corrugated pipe (1) Damaged, holes or cracks. Replace Coolant connections (2, 3) Traces of coolant leaks. Replace Output shaft (4) Damaged Replace Item Findings Measure Connector (1) Damaged Replace actuator. Actuator cable connection (2) Damaged Replace actuator. Protective cap not correctly Mount protective cap correctly.
  • Page 161 8.21.2 Engine governor and connector – Cleaning Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Solvent (isopropyl alcohol) X00058037 NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! •...
  • Page 162 8.21.3 Engine governor plug connections – Check Preconditions ☑ Engine stopped and starting disabled. ☑ Electronic engine management system is de-energized. NOTICE Insertion of unsuitable test probe, e.g. test prod. The contacts in the plug connection can be bent! • Carry out check of plug connection only with test connectors. Checking plug connections at engine governor Check all plug connections for secure seating.
  • Page 163 8.21.4 Resetting CDC parameter and entering IIG with DiaSys® Preconditions ☑ Engine is stopped and starting disabled. Note: If the parameters for the drift correction (CDC) are not reset, the emission certification becomes invalid. Resetting parameters for drift correction (CDC) with DiaSys® Use DiaSys®...
  • Page 164 8.21.5 NOx sensor – Replacement Preconditions ☑ Engine is stopped and starting disabled. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 4–20 Nm F30044239 Torque wrench, 10–60 Nm F30452769 Ratchet adapter F30027340 Assembly compound (Molykote P 37) 50564 NOx sensor (→...
  • Page 165 Installing NOx sensor Note: Note the following: • If the sensor (3) was subjected to shock or impact load, it is considered to be defective and may not be used. • Always replace NOx sensor (3) together with control unit (1). Install control unit (1) at the eyelets and tighten screws to the specified tightening torque.
  • Page 166 8.21.6 Lambda sensor – Replacement Preconditions ☑ Engine is stopped and starting disabled. ☑ Power supply to electronic engine management system is switched off. Special tools, Material, Spare parts Designation / Use Part No. Qty. Torque wrench, 10–60 Nm F30452769 Ratchet adapter F30027340 Assembly compound (Molykote P 37)
  • Page 167 Installing Lambda sensor Note: When the sensor was subjected to shock or impact load, it is deemed to be defective and may not be used. Remove protective cap on thread only just before installation. Note: Do not wipe off the thread lubricant applied by the manufacturer.
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  • Page 169 9 Manufacturer's Documentation Prefilter Installation Instructions ................................Prefilter Installation, Operation ................................MS15043/00E 2016-04 | Manufacturer's Documentation | 169...
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  • Page 171: Installation Instructions

    Collar Wrench WIF Plug (not shown) Electric Heaters (optional) WIF (optional) MTU America 39525 MacKenzie Drive, Novi, MI 48377 Customer support: 248-560-8200 F1862MTU REV 9 MS15043/00E 2016-04 | Manufacturer's Documentation | 171...
  • Page 172 Industrial Pro Installation Instructions “SEEING IS BELIEVING” ® • See when NOT to change the fuel filter. • See the condition of the fuel. Seeing what collects on the filter media or what’s happening inside the clear cover can help diagnose many fuel and mechanical conditions. •...

  • Page 173: Installation Steps

    Industrial Pro Installation Instructions Fuel Processor Installation Installation Steps This system must be installed between the fuel tank and 1. With the engine shut down and at ambient tempera- the transfer fuel pump on the suction side of the fuel sys- ture, close the fuel shutoff valve (if equipped) and tem.
  • Page 174 Industrial Pro Installation Instructions 5. Securely mount the Industrial Pro using twelve bolts . If the fuel hoses are made up to length on the (3/8"-24UNF or M10). (See Figure 1) job, be sure that the inner liner of the fuel hose is not cut by the fitting, creating potential check valve effects.
  • Page 175 Industrial Pro Installation Instructions Installing a WIF (Water In Fuel) Sensor With Optional Indicator (LED) E WARNING: Fuels are combusible. 5. Connect the XF70 plug of the WIF sensor harness (Figure 4) (5) to the XF70 connector on the engine and •...
  • Page 176 Industrial Pro Installation Instructions Priming Pump Electrical Specifications Supply Voltage: 24V Maximum Current 6A@24V Recommended Fuse: 10 Amp A (+) RED WIRE 24VDC B (-) BLACK WIRE DEUTSCH CONNECTOR #DT04-2P FUEL IN M12 X 1.5-6H THD. FUEL OUT M12 X 1.5-6H THD. Figure 5 - Priming Pump Electrical Connections 176 | Manufacturer's Documentation | MS15043/00E 2016-04...
  • Page 177 Industrial Pro Installation Instructions Primer Pump Service Assembly E WARNING: Fuels are combusible. 1. Install the new primer pump with fuel flow arrow aimed • RISK OF FIRE OR EXPLOSION: towards fuel outlet. (See Figure 7) • Avoid open flames, electrical sparks or igni- tion sources •...
  • Page 178 Industrial Pro Installation Instructions Installing an Optional Electric Heater E WARNING: Fuels are combusible. Note: When wiring the electric preheater, use a fuse NOT a circuit breaker. • RISK OF FIRE OR EXPLOSION: Industrial Pro 25 A • Avoid open flames, electrical sparks or igni- Fuse* tion sources 30/51...
  • Page 179 Industrial Pro Installation Instructions Filter Change Procedure E WARNING: Fuels are combusible. • RISK OF FIRE OR EXPLOSION: • Avoid open flames, electrical sparks or igni- tion sources Keyway Note: Do not smoke. Change the filter only when the fuel level reaches and remains at the top of the black band on the filter.
  • Page 180 Industrial Pro Installation Instructions Draining Contaminants Torque Values 1. Turn off the engine and open the vent cap. Application Torque 2. Place a suitable container under the drain valve at the ft-lb base of the Industrial Pro and open the drain valve. WIF Probe to Housing 3.
  • Page 181 Industrial Pro Installation Instructions Dimensions 6 . 0 0 1 5 2 . 4 R E C O M M E N D E D 4 . 2 0 M IN . S E R V IR E H E IG H T 5 .
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  • Page 195 Abgasturbolader/Abgasturboaufladung Exhaust turbocharger/exhaust turbocharging Air Temperature Sensor Baureihe Series Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publica- tion No. A01061/.. Controller Area Network Data bus system, bus standard Calibration Drift Compensation Drift correction setting with DiaSys in engine gover- Check Engine Lamp...
  • Page 196 Abbre- Meaning Explanation viation Engine Control Unit Engine governor Engine Data Module Memory module for engine data Electrically Erasable Programmable Read Electrically Erasable Programmable Read Only Mem- PROM Only Memory EFPA Electronic Foot Pedal Assembly Electronic accelerator pedal Exhaust Gas Recirculation Engine Ident Label EIM-ID Emission Identification Number Engine Monitoring Unit...
  • Page 197 Abbre- Meaning Explanation viation Not Applicable Low Pressure Normal Null Reference surface for heights above sea level Niedertemperatur Low temperature Original Equipment Manufacturer Optimized Idle Oil Level Sensor Monitors oil level Oil Pressure Sensor Monitors oil pressure Oil Temperature Sensor Monitors oil temperature Oberer Totpunkt Top Dead Center...
  • Page 198 Local Support Experienced and qualified specialists place their knowledge and expertise at your disposal. For locally available support, go to the MTU Internet site: http://www.mtu-online.com 24h Hotline With our 24h hotline and high flexibility, we're your contact around the clock: during each operating phase, preventive maintenance and corrective operations in case of a malfunction, for information on changes in conditions of use and for supplying spare parts.
  • Page 199 10.3 Conversion tables Length Unit A multiplied by factor = Unit B 25.4 = mm 0.3048 0.9144 stat. mile 1.609 = km 1.852 = km = ft = in Unit B multiplied by factor = Unit A 0.03937 = in 3.281 = ft 0.6215...
  • Page 200 Volumetric flow Unit A multiplied by factor = Unit B gal/min (GPM, U.S.) 3.79 = l/min gal/min (GPM, U.S.) 0.134 = ft /min (cfm) 1.70 /min (cfm) Unit B multiplied by factor = Unit A l/min 0.264 = gal/min (U.S.) 7.48 = gal/min (U.S.) /min (cfm)
  • Page 201 Density Unit A multiplied by factor = Unit B 515.4 slug/ft = kg/m Unit B multiplied by factor = Unit A 0.00194 kg/m = slug/ft Torque Unit A multiplied by factor = Unit B lbf ft 1.3558 = Nm Unit B multiplied by factor = Unit A 0.7376...
  • Page 202 Unit B multiplied by factor = Unit A 0.7376 = lbf ft 0.0002388 = kcal 0.0009478 = BTU 0.00052656 = CHU Power Unit A multiplied by factor = Unit B 0.7355 = kW 0.7457 = kW BTU/s 1.054 = kW kcal/h 1.163 = lbf ft/s...
  • Page 203 10.4 Tightening specifications for screws, nuts and bolts Tightening torques for setscrew and stud joints to MTN 5008 standard This standard applies to setscrews not subject to dynamic loads and the associated nuts according to: • MMN 384 • ISO 4762 (DIN 912) •...
  • Page 204 Hand-tightening Machine-tightening Thread 8.8 M (Nm) 10.9 M (Nm) 8.8 M (Nm) 10.9 M (Nm) M20 x 1.5 M22 x 1.5 M24 x 1.5 M24 x 2 1250 1175 M27 x 2 1350 1275 1200 1700 1100 1600 M30 x 2 1350 1900 1250...
  • Page 205 Tightening torque for self-locking hex nuts (Nm) Thread Lubricant 7,5 +1 – 17 +2 – 35 +4 – 59 +6 – 100 +10 – 140 +14 – 290 +29 – = tightening torques Tightening torques for stress bolt connections to MTN 5007 standard This standard applies to stress pin bolts and stress bolts which are subjected to static and dynamic load of strength class 10.9 as well as to the associated nuts.
  • Page 206 Not torsion-protected M (Nm) Torsion-protected M (Nm) Thread 1250 1575 *Protect screw shaft from torsion when tightening. = tightening torques Tightening torques for plug screws to MTN 5183-1 standard This standard applies to plug screws to DIN 908, DIN 910 and DIN 7604 with threaded end to DIN 3852 Form A (sealed with sealing ring to DIN 7603-Cu).
  • Page 207 Tightening torques M are given for screw plugs made of steel (St) with surface protected by a phosphate coating and oiled or galvanized. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.
  • Page 208 Screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M64 x 2 = tightening torques Tightening torques for plug screws to DIN 7604C (with long threaded end) Screwed into Thread Steel/gray cast iron M Al alloy M (Nm) (Nm) M8 x 1...
  • Page 209 The stated tightening torques M apply to steel (St) banjo screws with a phosphatized surface coating and oiled, or galvanized, and to banjo screws made of copper/aluminum alloys. Threads and mating faces beneath heads must be coated with engine oil prior to assembly. An assembly tolerance of +10% of the figures in the table is permitted due to unavoidable deviations during the tightening process.
  • Page 210 Tightening torques for male unions to MTN 5183-3 standard This standard applies to male unions to DIN 2353 Series L with threaded end to DIN 3852 Form A (sealed by sealing ring to DIN 7603-Cu). Tightening torques M are given for male unions made of steel (St) with phosphatized surface coating and oiled, or galvanized.
  • Page 211 Tightening torques for union nuts to DIN 3859-2 1 Union nut 2 Union body 3 O-ring 4 Ferrule Union nut: On installing the ball-type union, after tightening the union nut firmly by hand (noticeable increase in force), it should be tightened another 1/4 turn (90°) past this point. Tightening torques for spigot unions with O-ring to ISO 6149-2 Thread Torque (Nm) +10%...
  • Page 212 Thread Torque (Nm) +10% M27 x 2 M33 x 2 M42 x 2 M48 x 2 M60 x 2 Only for sealing off installation spaces for screw-in valves (see ISO 6149-47 and ISO 7789) Tightening torques for spigot unions with O-ring to ISO 6149-3 Thread Torque (Nm) +10% M8 x 1...
  • Page 213 Tightening torques for plug screws to MTN 5183-6 Screwed into Thread Steel/gray cast iron M AI alloy M (Nm) (Nm) M10 x 1 10 +2 M12 x 1.5 14 +2 M14 x 1.5 15 +3 M16 x 1.5 18 +3 M18 x 1.5 23 +3 M22 x 1.5...
  • Page 214 Sealing head/sealing cone with metric union nut Metric thread Pipe outer dia. Torque (Nm) M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 1.5 M26 x 1.5 M30 x 2 M36 x 2 M42 x 2 M45 x 2 M52 x 2 Sealing head with BSP union nut...
  • Page 215 ORFS – flat sealing with union nut UNF thread Size Torque (Nm) 9/16–18 –4 14 +2 11/16–16 –6 24 +3 13/16–16 –8 43 +4 1–14 –10 60 +8 1.3/16–12 –12 90 +5 1.3/16–12 –14 90 +5 1.7/16–12 –16 125 +10 1.11/16–12 –20 170 +20...
  • Page 216 11 Appendix B 11.1 Special Tools Angular screw driver Part No.: F30002815 Qty.: Used in: 8.6.3 Valve clearance – Check and adjustment (→ Page 96) Barring device Part No.: F6555766 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 78) Qty.: Used in: 8.2.1 Cylinder liner –...
  • Page 217 Barring device Part No.: F6792918 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 78) Barring device Part No.: F6798050 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 78) Belt tension tester (optibelt TT3) Part No.: Y4345711 Qty.: Used in: 8.18.1 Fan drive –...
  • Page 218 Crossbeam Part No.: T80092210 Qty.: Used in: 2.1 Transportation (→ Page 16) Depth gauge, 200 mm Part No.: Y20000918 Qty.: Used in: 8.6.2 Valve protrusion – Measurement (→ Page 94) Endoscope Part No.: Y20097353 Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 84) Feeler gage Part No.: Y20098771...
  • Page 219 Filter wrench Part No.: F30379104 Qty.: Used in: 8.9.1 Fuel filter – Replacement (→ Page 108) Qty.: Used in: 8.9.2 Additional fuel filter – Replacement (→ Page 109) High-pressure cleaning unit Part No.: Qty.: Used in: 5.7 Plant – Cleaning (→ Page 43) Installation/removal jig Part No.: F6796646...
  • Page 220 MTU test kit Part No.: 5605892099/00 Qty.: Used in: 8.13.4 Engine oil – Sampling and analysis (→ Page 123) Ratchet adapter Part No.: F30027340 Qty.: Used in: 2.3 Crankshaft – Transport locking device (→ Page 18) Qty.: Used in: 8.11.4 Exhaust flaps – Coupling rod replacement (→...
  • Page 221 Ratchet with extension Part No.: F30006212 Qty.: Used in: 8.1.1 Engine – Barring manually (→ Page 78) Qty.: Used in: 8.2.1 Cylinder liner – Endoscopic examination (→ Page 84) Socket wrench, 24 mm Part No.: F30039526 Qty.: Used in: 8.6.3 Valve clearance – Check and adjustment (→...
  • Page 222 Torque wrench, 10–60 Nm Part No.: F30452769 Qty.: Used in: 2.3 Crankshaft – Transport locking device (→ Page 18) Qty.: Used in: 8.3.1 Oil mist fine separator – Replacement (→ Page 88) Qty.: Used in: 8.7.2 Injector – Removal and installation (→ Page 102) Qty.: Used in: 8.14.3 Centrifugal oil filter –...
  • Page 223 Torque wrench, 60–320 Nm Part No.: F30452768 Qty.: Used in: 2.3 Crankshaft – Transport locking device (→ Page 18) Qty.: Used in: 8.6.3 Valve clearance – Check and adjustment (→ Page 96) Qty.: Used in: 8.7.2 Injector – Removal and installation (→ Page 102) Qty.: Used in: 8.18.1 Fan drive –...
  • Page 224 11.2 Index Crankshaft  – Transport locking device   Abbreviations 195 – Installation  18 Actuators  – Removal  18 – Function test  159 Cylinder  – Overview  24 – Designation  21 – Visual inspection  159 Cylinder head cover  Additional fuel filter  – Removal and installation  99 –...
  • Page 225  163 Fan drive  Plant  – Replacement   – Cleaning  43 – Drive belt  154 Product data  – Tension check / adjustment   – 20V4000C55  28 – Drive belt  151 – 20V4000C65  31 Fault messages  Pump  – ECU9  49 – Charge-air coolant  ...
  • Page 226 Service partners 198 Spare parts service 198 Starter  – Condition check  118 Starting system  – Engine cranking  81 Technical data  – 20V4000C55  28 – 20V4000C65  31 Tightening specifications  – Nuts  203 – Screws and bolts  203 – Screws, nuts and bolts  203 Transport locking device ...

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